Frelander 2. Manual — part 102
Brake System - General Information -
Brake Hydraulic Fluid
CAUTION: * If the fluid shown is not available, use a low viscosity DOT 4 brake fluid meeting ISO 4925 Class 6 and
Land Rover LRES22BF03 requirements.
Item
Specification
Recommended hydraulic fluid*
SHELL DONAX YB DOT4 ESL FLUID
General Specification
Item
Specification
Front and rear calipers
Single piston sliding calipers
Operation
Hydraulic, self adjusting
Front disc
Ventilated
Rear disc:
3.2 Petrol
Ventilated
2.2 Diesel
Solid
Parking brake type
Manually applied cable operated system
Master cylinder and
booster:
Make
Continental Teves
Master cylinder type
Tandem design with independent (primary and secondary) hydraulic circuits
Booster type
Compact design with tandem diaphragms 203.20 mm (8.00 in) and 228.60 mm (9.00 in) in
diameter
Brake System - General Information - Brake System
Description and Operation
COMPONENT LOCATION
Item
Part Number
Description
1
-
Brake pedal, booster and master cylinder assembly
2
-
Parking brake lever
3
-
Rear disc brake and parking brake assembly
4
-
Anti-lock Brake System (ABS) module and Hydraulic Control Unit (HCU)
5
-
Front disc brake assembly
6
-
ABS speed sensor cable
INTRODUCTION
Vehicle braking is achieved with a vacuum assisted, hydraulic circuit connected via an integrated ABS module and HCU, to
the front and rear disc brake calipers. For increased safety, the hydraulic system is designed as a diagonally split dual
circuit. This provides a primary and secondary braking circuit connected between the master cylinder and each front and
opposing rear wheel.
The braking system provides anti-lock control to aid the driver, and to make sure the vehicle remains in control during all
driving conditions and manouevres. The sophisticated ABS functionality also integrates with other vehicle software
controlled systems, to provide stability assistance and control when driving off-road.
The parking brake is a manually applied cable system that operates brake shoes, housed within the inner diameter of each
rear brake disc.
FRONT AND REAR DISC BRAKES
The 3.2L i6 vehicle is installed with ventilated front and rear brake discs. The 2.2L TD4 vehicle is installed with ventilated
front and solid rear brake discs. Both the i6 and TD4 vehicles feature single piston, sliding calipers on all brake discs. For
additional information, refer to:
Front Disc Brake
(206-03 Front Disc Brake, Description and Operation),
Rear Disc Brake
(206-04 Rear Disc Brake, Description and Operation).
PARKING BRAKE
The parking brake is a manually applied, cable operated system. The RH and LH rear brake discs form the parking brake
drums, and provide the location for the parking brake shoes and components.
For additional information, refer to:
Parking Brake
(206-05 Parking Brake and Actuation, Description and Operation).
HYDRAULIC BRAKE ACTUATION
Hydraulic brake actuation consists of the brake pedal, master cylinder, HCU, and the connecting hydraulic pipes and hoses.
The tandem brake master cylinder with reservoir is attached to, and operated by the brake booster. The brake master
cylinder is a tandem design that supplies pressure to 2 independent (primary and secondary) hydraulic circuits.
For additional information, refer to:
Hydraulic Brake Actuation
(206-06 Hydraulic Brake Actuation, Description and
Operation).
BRAKE BOOSTER
The brake booster is vacuum operated and provides power assistance to the brake hydraulic system. The booster is of
tandem design that incorporates 2 separate diaphragms. On both the gasoline and diesel models, the vacuum required for
booster operation is produced by an engine driven, vacuum pump.
For additional information, refer to:
Brake Booster
(206-07 Power Brake Actuation, Description and Operation).
ANTI-LOCK CONTROL
The anti-lock control system features a Continental Teves Mk25E1 ABS module with integral 4 channel HCU. The ABS
module and HCU provide brake system monitoring, and active brake functions to control the vehicle stability and traction.
The ABS module also provides specific functions to assist the vehicle during off-road driving.
The anti-lock control system provides the following functions:
Anti-lock Brake System (ABS)
Corner Brake Control (CBC)
Dynamic Stability Control (DSC)
Electronic Brake Force Distribution (EBD)
Electronic Traction Control (ETC)
Emergency Brake Assist (EBA)
Engine Drag-Torque Control (EDC)
Hill Descent Control (HDC) with gradient release control
Roll Stability Control (RSC)
Terrain Response™ system integration.
For additional information, refer to:
Anti-Lock Control - Stability Assist
(206-09C Anti-Lock Control - Stability Assist,
Description and Operation).
Brake System - General Information - Brake System
Diagnosis and Testing
Principle of Operation
For a detailed description of the brake system, refer to the relevant Description and Operation section in the workshop
manual. REFER to:
Brake System
(206-00 Brake System - General Information, Description and Operation),
Front Disc Brake
(206-03 Front Disc Brake, Description and Operation),
Rear Disc Brake
(206-04 Rear Disc Brake, Description and Operation),
Parking Brake
(206-05 Parking Brake and Actuation, Description and Operation),
Hydraulic Brake Actuation
(206-06 Hydraulic Brake Actuation, Description and Operation),
Brake Booster
(206-07 Power Brake Actuation, Description and Operation).
Inspection and Verification
1. Verify the customer concern.
1.
2. Visually inspect for obvious signs of damage and system integrity.
2.
Visual Inspection
Mechanical
Electrical
Brake master cylinder
Brake caliper piston(s)
Brake discs
W heel bearings
Brake pads
Power brake booster
Vacuum pump
Brake pedal linkage
Brake booster vacuum hose
Tires
Damaged or corroded wiring harness
Brake master cylinder fluid level switch
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
3.
4. If the cause is not visually evident, verify the concern and refer to the Symptom Chart.
4.
Road Test
Carry out a road test to compare actual vehicle braking performance with the performance standards expected by the
driver. The ability of the test driver to make valid comparisons and detect performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of brake system operation and accepted general performance guidelines to
make good comparisons and detect performance concerns.
An experienced brake technician will always establish a route that will be used for all brake diagnosis road tests. The
roads selected will be reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not
allow the tires to grip the road equally. Crowned roads should be avoided because of the large amount of weight shifted to
the low set of wheels on this type of road. Once the route is established and consistently used, the road surface variable
can be eliminated from the test results.
Before a road test, obtain a complete description of the customer concerns or suspected condition. From the description,
the technician's experience will allow the technician to match possible causes with symptoms. Certain components will be
tagged as possible suspects while others will be eliminated by the evidence. More importantly, the customer description
can reveal unsafe conditions which should be checked or corrected before the road test. The description will also help form
the basic approach to the road test by narrowing the concern to specific components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Keeping the description of the concern in mind, test the
brakes at different vehicle speeds using both light and heavy pedal pressure.
If the concern becomes evident during this check, verify it fits the description given before the road test. If the concern is
not evident, attempt to duplicate the condition using the information from the description.
If a concern exists, refer to the Symptom Chart.
Symptom Chart
Symptom
Possible Cause
Action
Brakes noisy
Brake pads
Brake discs
GO to Pinpoint Test
A.
Vibration when brakes are
applied
Wheels/tires out of balance
Wheel hub nuts loose
Brake caliper mounting bolts loose
Brake pads
Foreign material/scratches/corrosion
on brake disc contact surfaces
Excessive brake disc thickness
GO to Pinpoint Test
B.
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